Method for providing patterns of functional materials

ABSTRACT

A method is used to provide a pattern of a functional material for example on a receiving element. To provide this pattern, a laser-engraveable patternable element is imagewise exposed with laser-engraving radiation. This element has a laser-engraveable layer comprising a thermoplastic elastomeric interpolymer alloy. This interpolymer alloy comprises a non-crosslinked halogenated polymer, a partially crosslinked polyolefin, and a polyester. A laser-engraved patterned element is formed that has a relief image in the laser-engraveable layer, and this relief image can be contacted with a suitable functional material that is then transferred to the receiving element to provide the desired pattern.

RELATED APPLICATION

Reference is made to copending and commonly assigned U.S. Ser. No. 13/627,140 filed on Sep. 26, 2012, by Rowley and Landry-Coltrain, and entitled DIRECT LASER-ENGRAVEABLE PATTERNABLE ELEMENTS AND USES.

FIELD OF THE INVENTION

This invention relates to a method for providing a pattern of a functional material particularly on a suitable substrate or receiver element. The pattern can be provided using a direct laser-engraveable patternable element having a unique composition in the laser-engraveable layer.

BACKGROUND OF THE INVENTION

Relief images can be provided and used in various articles for many different purposes. For example, the electronics, display, and energy industries rely on the formation of coatings and patterns of conductive materials to form circuits on organic and inorganic substrates. Such coatings and patterns are often provided using relief imaging methods and relief image forming elements. There is also need for means to provide fine wiring in various articles.

Microelectronic devices have been prepared by photolithographic processes to form necessary patterns. Photolithography, however, is a complex, multi-step process that is too costly for the printing of electronic devices on plastic substances.

Contact printing is a flexible, non-lithographic method for forming patterned materials. Contact printing potentially provides a significant advance over conventional photolithographic techniques since contact printing can form relatively high resolution patterns for electronic parts assembly. Microcontact printing can be characterized as a high resolution technique that enables patterns of micrometer dimensions to be imparted onto a substrate surface. Contact printing is a possible replacement to photolithography in the fabrication of microelectronic devices, such as radio frequency tags (RFID), sensors, and memory and back panel displays. The capability of microcontact printing to transfer a self-assembled monolayer (SAM) forming molecular species to a substrate has also found application in patterned electroless deposition of metals. SAM printing is capable of creating high resolution patterns, but is generally limited to forming metal patterns of gold or silver for example using thiol chemistry. Although there are variations, in SAM printing a positive relief pattern provided on an element having a relief image is inked onto a substrate.

Flexography is a one method of printing or pattern formation that is commonly used for high-volume printing runs. It is usually employed for printing on a variety of soft or easily deformed materials including but not limited to, paper, paperboard stock, corrugated board, polymeric films, fabrics, metal foils, glass, glass-coated materials, flexible glass materials, and laminates of multiple materials. Coarse surfaces and stretchable polymeric films are economically printed using flexography.

Flexographic printing members are sometimes known as “relief” printing members (for example, relief-containing printing plates, printing sleeves, or printing cylinders) and are provided with raised relief images onto which ink is applied for application to a printable material. While the raised relief images are inked, the relief “floor” should remain free of ink. The flexographic printing precursors are generally supplied with one or more imageable layers that can be disposed over a backing layer or substrate. Flexographic printing also can be carried out using a flexographic printing cylinder or seamless sleeve having the desired relief image.

Gravure or intaglio printing members are also relief printing members in which the image to be printed comprises depressions or recesses on the surface of the printing member, where the printing area is localized to the areas of depression that define the pattern or image. The process for using gravure or intaglio printing members is the reverse of flexographic relief printing wherein an image is raised above the floor of the flexographic printing member and the printing area is localized at the contact area of the top surface protrusions.

Laser ablation or laser engraving can be used effectively with an appropriate laser-engraveable precursor to form images for either of the above-mentioned printing processes.

Flexographic printing precursors having laser-ablatable layers are described for example in U.S. Pat. No. 5,719,009 (Fan) where precursors include a laser-ablatable mask layer over one or more photosensitive layers. This publication teaches the use of a developer to remove non-reacted material from the photosensitive layer, the barrier layer, and non-ablated portions of the mask layer.

There has been a desire in the industry for a way to prepare flexographic printing members without the use of curable photosensitive layers that require liquid processing to remove non-imaged composition and mask layers and that generate significant amount of liquid waste. Direct laser engraving of precursors to produce relief printing plates and stamps is known, but the need for relief image depths greater than 500 μm creates a considerable challenge when imaging speed is also an important commercial requirement. In contrast to laser ablation of mask layers that require low to moderate energy lasers and fluence, direct engraving of a relief-forming layer requires much higher energy and fluence. A direct laser-engraveable layer must also exhibit appropriate physical and chemical properties to achieve “clean” and rapid laser engraving (high sensitivity) so that the resulting printed images have excellent resolution and durability.

A number of elastomeric systems have been described for construction of laser-engraveable flexographic printing precursors using various elastomeric rubber compositions in the laser-engraveable layers as described for example, in U.S. Pat. No. 6,223,655 (Shanbaum et al.), U.S. Pat. No. 4,934,267 (Hashimoto), and U.S. Pat. No. 5,798,202 (Cushner et al.). Although many polymers are suggested for this use in the literature, only extremely flexible elastomers have been used commercially because flexographic layers that are many millimeters thick must be designed to be bent around a printing cylinder and secured with temporary bonding tape and both must be removable after printing.

Thermoplastic elastomeric composition comprising partially crosslinked blends of ethylene copolymers and vinyl or vinylidene halide polymers are described in U.S. Pat. No. 4,613,533 (Loomis et al.), U.S. Pat. No. 4,739,012 (Hagman), and U.S. Pat. No. 7,282,242 (Abell, III, et al.).

U.S. Patent Application Publication 2008/0233280 (Blanch et al.) describes the use of functional materials to form patterns on substrate by specific treatments of the stamp used to make the pattern.

The vulcanization of rubbers is a time-consuming, labor-intensive, multi-step process with significant batch-to-batch variations. Inconsistencies in curing and components lead to considerable waste in manufacturing, which brings increased costs and environmental problems. In addition, vulcanization requires the use of various sulfur or peroxide vulcanization agents, but such reactive compounds can produce objectionable odors. In general, the vulcanized compositions known in the art are non-processable, non-reshapeable, and non-recyclable.

Polyvinylchloride is a thermoplastic polymer but it has a glass transition temperature that is above ambient temperature and is therefore a rigid thermoplastic polymer and thus does not offer the flexibility, elongation, and compression recovery properties required for flexographic printing plates or other printing plates that need to be wrapped around a print cylinder. Polychloroprene (or neoprene) offers excellent compressability and elongation, but it is a vulcanized (or crosslinked) rubber and therefore it is a thermoset polymer, which cannot be readily re-melted and reprocessed into another printing plate precursor.

There is a need to avoid the problems associated with conventional vulcanizing processes and to provide direct laser-engraveable compositions that are useful for providing relief images and that can be prepared with reduced material waste and even recycled for re-use.

SUMMARY OF THE INVENTION

This invention provides a method for providing a pattern of a functional material, the method comprising:

imagewise exposing a laser-engraveable patternable element that comprises at least one laser-engraveable layer comprising a thermoplastic elastomeric interpolymer alloy that comprises:

a non-crosslinked halogenated polymer,

a partially crosslinked polyolefin, and

a polyester,

to laser-engraving radiation to provide a directly laser-engraved patterned element having a relief image in the laser-engraveable layer, and

using the directly laser-engraved patterned element to print a pattern of a functional material.

This method can be used to provide an element having a printed pattern of a functional material.

The laser-engraveable patternable element used in the method of this invention provides a combination of desirable properties that are essential for high precision patterning or engraving using laser engraving. It is generally considered that a laser-engraveable flexographic printing plate precursor must be cross-linked, hardened, or vulcanized in order to prevent the formation of melt edges during laser ablation (imaging) and to prevent excessive material swelling by printing functional materials during printing and by printing plate cleaning solvents.

It is a recognized problem that cross-linked, hardened, or vulcanized materials cannot easily be reprocessed, reformed, re-used, or recycled to their original material. It is also recognized that manufacturing difficulties, such as premature set-up, incomplete cure, and short pot-life, occur with the use of thermosetting elastomer precursors when preparing thick flexographic printing plates.

The composition used in the laser-engraveable layer according to this invention provides a solution to these problems. This laser-engraveable composition is totally melt-processable, unlike vulcanized rubbers that cannot be re-melted and processed and this allows for the laser-engraveable patternable element or material to be easily recycled into a new laser-engraveable patternable element comprising the same laser-engraveable composition. The recycling capability is particularly important for printing functional materials using short run lengths and multiple media turnovers. Disposing of used patterned materials would produce significant amount of waste, and the present invention reduces that waste.

Laser engraving of this composition during imaging provides excellent quality images with clean, precise features and no melt edges around the imaged features. It also provides surprisingly low debris accumulation and low sticking of the ablated debris onto the patterned element, which effects would result in image and print quality degradation. The presence of dirt or other debris on the laser engraved patterned element used for printing would potentially result in a defect that would affect the performance of the printed device, such as a break in a printed conductive line that would result in an electrical short. The laser-engraveable composition used according to this invention provides excellent laser-engraving efficiency, allowing for acceptable imaging throughput.

The laser-engraveable composition used according to this invention has excellent compressibility and elastomeric properties, similar to vulcanized rubbers, which properties are critical for flexographic printing. The laser-engraveable patternable elements used in the practice of this invention can be readily embossed, with good release properties from the stamp or mold, to create a patterned surface that will enhance print quality, particularly in solids areas.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

As used herein to define various components of the laser-engraveable compositions, formulations, layers, and functional materials unless otherwise indicated, the singular forms “a”, “an”, and “the” are intended to include one or more of the components (that is, including plurality referents).

Each term that is not explicitly defined in the present application is to be understood to have a meaning that is commonly accepted by those skilled in the art. If the construction of a term would render it meaningless or essentially meaningless in its context, the term's definition should be taken from a standard dictionary.

The use of numerical values in the various ranges specified herein, unless otherwise expressly indicated otherwise, are considered to be approximations as though the minimum and maximum values within the stated ranges were both preceded by the word “about”. In this manner, slight variations above and below the stated ranges can be used to achieve substantially the same results as the values within the ranges. In addition, the disclosure of these ranges is intended as a continuous range including every value between the minimum and maximum values.

Unless otherwise indicated, percentages refer to percents by total dry weight, for example, weight % based on total solids of a layer, composition, or formulation. Unless otherwise indicated, the percentages can be the same for either the dry layer or the total solids of the formulation or composition used to make that layer.

In some embodiments, the term “imaging” refers to ablation of the background areas while leaving intact the areas of the laser-engraved patterned material that can be contacted with a functional material to provide a desired pattern.

Alternatively the term “imaging” refers to ablation of the image areas that can be inked up using a suitable functional material (for pattern formation) while leaving intact the areas of the laser-engraved patterned material that will not be printed, such as in gravure or intaglio printing members.

The term “flexographic printing precursor” refers to some embodiments of laser-engraveable patternable elements. The flexographic printing precursors include flexographic printing plate precursors, flexographic printing sleeve precursors, and flexographic printing cylinder precursors, all of which can be directly laser-engraved to provide a relief image using a laser to have a minimum relief image depth of at least 30 μm and up to and including 4000 μm, or at least 50 μm to and including 3000 μm. Such directly laser-engraveable, relief-forming precursors can also be known as “flexographic printing plate blanks”, “flexographic printing cylinders”, or “flexographic sleeve blanks”. The laser-engraveable flexographic printing precursors can also have seamless or continuous forms.

The term “laser-engraveable” means that a layer can be directly imaged using a suitable laser-engraving source including carbon dioxide lasers and near-infrared radiation lasers such as Nd:YAG lasers, laser diodes, and fiber lasers. Absorption of energy provided by these lasers produces heat that causes rapid local changes in the laser-engraveable layer so that the imaged regions are physically detached from the rest of the layer or substrate and ejected from the layer and collected using suitable means. Non-imaged regions of the laser-engraveable layer are not removed or volatilized to an appreciable extent and thus form the upper surface of the relief image that is the patterned element printing surface for printing. The breakdown is a violent process that includes eruptions, explosions, tearing, decomposition, fragmentation, oxidation, or other destructive processes that create a broad collection of solid debris and gases. This is distinguishable from, for example, image transfer. “Laser-ablative” and “laser-engraveable” can be used interchangeably in the art, but for purposes of this invention, the term “laser-engraveable” is used to define imaging in which a relief image is formed in the laser-engraveable layer. It is distinguishable from image transfer methods in which ablation is used to materially transfer pigments, colorants, or other image-forming components. The present invention relies on “direct” laser engraving of the relief-forming laser-engraveable layer, and it is distinguished from laser ablation of a thin layer to create a mask that is used to control the application of curing radiation to underlying layers and is removed prior to printing.

Unless otherwise indicated, the terms “laser-engraveable composition” and “laser-engraveable layer formulation” are intended to be the same.

The “top surface” is equivalent to the “relief-image forming surface” and is defined as the outermost surface of the laser-engraveable patternable element and is generally the first surface that is struck by imaging (engraving) radiation during the laser-engraving process. The “bottom surface” is defined as the surface of the laser-engraveable patternable element that is most distant from the imaging radiation.

As used herein, the term “recyclable” means that the laser-engraveable patternable element or laser-engraved patterned element can be reprocessed by melting and forming a new laser-engraveable patternable element with essentially the same laser-engraveable composition as the original. In the strictest sense, recycling of such a laser-engraveable material would produce a fresh supply of the same laser-engraveable material. It is understood, however, that for specific intended purposes, other additives can be also incorporated during the recycling process.

Uses

The method of this invention can be used in many ways to form a pattern of a functional material on a suitable receiver element or substrate for use in devices and components in a variety of applications including but not limited to, electronic, optical, sensory, and diagnostic devices. More details of such uses are provided below. A variety of active and inactive materials as the functional material can be applied to the receiver material using a laser-engraved patterned element described herein. In particular, it is desired to use the present invention to provide patterns on receiver elements with line resolution of less than 50 μm and even less than 20 μm.

Such electronic and optical devices and components include but are not limited to, radio frequency tags (RFID), sensors, and memory and back panel displays. The method of this invention can be used to form patterns of electrically conductive materials, semi-conductive materials, and dielectric materials.

The method of this invention can be used to form patterns of biological materials and pharmacologically active materials on a receiver element for use in sensory or diagnostic applications. The method can form the functional material into a pattern that forms barrier walls for cells or pixels to contain other materials, such as light emitting materials, color filter pigmented materials, or a pattern that defines the channel length between source and drain electrode delivered from solution. The pattern of barrier walls can also be referred to as a confinement layer or barrier layer. The method of this invention can be used to form a functional material into a pattern that forms barrier walls that create cells for use as color filter pixels. The color filter pixels can be filled with colorants for color filters, including dye colorants and pigment colorants.

The present invention can also be used to form a functional material into transistor channels for top gate devices in which other materials, such as source materials and drain materials, are delivered to the channels. The method can form the functional material into transistor channels on a semiconducting layer of the receiver element for bottom gate devices in which source materials and drain materials are delivered to the channels. The other materials can be delivered into cells on a receiver element by any means including ink jetting.

The present invention is also useful for providing electrically conductive patterns on receiver elements such as elements designed for use as touch panel displays. Such electrically conductive patterns can be provided using functional materials that are, or can be processed or treated in some manner to become, electrically conductive such as metals and metallic salts. Useful functional materials of this type include but are not limited to, silver and silver salts such as silver halides and silver behenate.

Functional Materials

The term “functional material” refers to a material that is capable of facilitating an operation in a component or device. In addition, a functional material is used for purposes other than simply providing visual information. The functional material can be an active or inactive material, and can be organic or inorganic in nature. Organic materials can be polymeric materials or non-polymeric small molecules, or oligomeric materials in between. “Active materials” include but are not limited to, electrically active materials, photoactive materials, and biologically active materials. As used herein, the terms “electrically active”, “photoactive”, and “biologically active” refer to a material that exhibits a predetermined activity in response to a stimulus, such as an electromagnetic field, an electrical potential, solar or other energy radiation, a biostimulation field, or any combination thereof.

“Inactive materials” include but are not limited to, insulating materials such as dielectric materials, planarization materials, barrier materials, and confinement materials. For example, a planarization material can be printed on top of a pattern of pixels in color filters to render all pixels the same height. A barrier material is a printed pattern that forms a barrier so that charges in the cathode facilitate charge injection into a light emitting polymer layer in an organic light emitting diode (OLED). A confinement material can be printed as a pattern that restricts the expansion of a subsequently applied liquid to a particular area that is defined by the pattern of confinement material.

Functional materials include for example, electrically conductive materials, electrically semi-conductive materials, and dielectric materials. Examples of electrically conductive materials include but are not limited to, conductive polymers, indium-tin oxide, metals such as gold, silver, copper, and palladium, metal complexes, and metal alloys. A functional material can alternatively be a conductive material precursor such as a metal salt (for example a silver salt like a silver halide), or an electroless metallization catalyst such as palladium particles. Examples of useful electrically semi-conductive inorganic materials include but are not limited to silicon, germanium, gallium arsenide, zinc oxide, and zinc selenide.

Examples of useful electrically semi-conductive organic materials that can be used as functional materials include N,N′-di(arylalkyl)-substituted naphthalene-based tetracarboxylic diimide compounds as described for example in U.S. Pat. No. 7,981,719 (Shukla et al.), N,N′-cycloalkyl-substituted naphthalene-based tetracarboxylic diimide compounds as described for example in U.S. Pat. No. 8,212,243 (Shukla et al.), and compositions also containing polymer additives as described for example in U.S. Patent Application Publication 2011-0183462 (Shukla et al.), all of which are incorporated herein by reference.

In addition the photocurable inks described in U.S. Patent Application Publication 2012-0207935 (Shukla et al.) that is incorporated herein by reference, can be used as functional materials.

Useful functional materials can also be compositions that can be polymerized by photoinitiation such as those described in U.S. Patent Application Publication 2012-0122664 (Shukla et al.) that is incorporated herein by reference.

Further, “precursor” compositions such as amic acid or amic acid ester compositions can be used as functional materials as described for example in U.S. Patent Application Publication 2011-0269967 (Shukla et al.) that is incorporated herein by reference.

Functional materials can be of any form including particulate, polymeric, small molecule, and other forms that would be apparent to a skilled worker. For example, electrically semi-conductive materials and dielectric materials are polymer materials.

Useful polymeric functional materials include electrically conductive polymers including but not limited to, homopolymers and copolymers comprising polythiophenes, polyanilines, polypyrroles, polycarbazoles, polyindoles, polyazepines, polyethylenedioxythiophenes, poly(3-alkylthiophenes), poly(p-phenylene vinylene)'s, polyp-phenylene)'s, poly(styrene sulfonic acid) (PSS), poly(p-phenylene sulfide), polyacetylene, poly(3,4-ethylene dioxythiophene) (PEDOT), and a mixture of poly(styrene sulfonic acid) and poly(3,4-ethylene dioxythiophene) (PSS:PEDOT).

It is also possible that the functional materials are nanoparticles of electrically conductive, electrically semi-conductive, and dielectric materials. Nanoparticles are microscopic particles whose size is measured in nanometers (nm). Nanoparticles include particles having at least one dimension less than 200 nm. In some embodiments, the nanoparticles have an average diameter of at least 3 nm to and including 100 nm. The nanoparticles can be in the form of clusters. The shape of the nanoparticles is not limited and includes nanospheres, nanorods, and nanocups. Nanoparticles composed of electrically semi-conductive materials can also be known as quantum dots if the particles are small enough (usually less than 30 nm) that quantization of electronic energy levels occurs. Electrically conductive semi-conductive materials include light-emitting quantum dots. The functional materials include but are not limited to, semi-solid nanoparticles such as liposomes, soft nanoparticles, nanocrystals, and hybrid structures, such as core-shell nanoparticles. Moreover, the functional materials also include nanoparticles of carbon such as carbon black, carbon nanotubes, electrically conducting carbon nanotubes, graphene, carbon black conducting polymers, and electrically semi-conducting nanotubes. Metal nanoparticles and dispersions of gold, silver, and copper are also useful.

The term “photoactive” functional material is intended to mean any functional material that exhibits photoluminescence, electroluminescence, or photosensitivity. The term is intended to include at least dyes, optical whiteners, photoluminescent materials, compounds reactive to actinic radiation, and photoinitiators. For example, a photoactive functional material can be a material or combination of materials that are capable of initiating one or more reactions, particularly photochemical reactions, upon response to suitable ultraviolet, visible, or infrared radiation. Photoactive functional materials can include compounds that can be reactive to radiation or a composition comprising one or more compounds, such as monomers and photoinitiators that render the composition reactive to the radiation.

Further examples of functional materials can be referred to as small molecules and can include but are not limited to, organic dyes, electrically semi-conducting molecules, fluorescent chromophores, phosphorescent chromophores, pharmacologically active compounds, biologically active compounds, silver halide compositions, and compounds having catalytic activities, that alone or in various combinations with other materials, are suitable for the fabrication of patterned devices useful for electronic, sensory, or diagnostic applications.

Biologically active materials, which can also be called bio-based materials, for use in the present invention can include but are not limited to, deoxyribonucleic acids (DNA's) of various molecular weights that can be used as templates or scaffolds to position other materials that bind to DNA into well-defined geometries, and proteins, poly(oligo) peptides, and poly(oligo)saccharides, that alone or in various combinations with other materials, are suitable for the fabrication of patterned devices for electronic, sensory, or diagnostic applications.

If not already in liquid form, a functional material can be dispersed or dissolved or suspended in a liquid, forming a composition for application to a receiver material using the laser-engraved patterned element described herein. The liquid used for the functional material is not limited and can include organic compounds and aqueous compounds. For example, the liquid can be an organic compound that is an alcohol-based compound. The liquid can be a solvent that is capable of dissolving another substance such as one or more functional materials to form a uniform mixture, or it can be a carrier compound capable of dispersing or suspending the functional material is solution sufficient to carry out the method of this invention.

The liquid, whether a solvent or carrier, and the functional material should at least be capable of wetting at least the raised surface of the relief image during the method of this invention.

The liquid can also include one or more compounds as a solvent or carrier for the functional material. For example, the liquid can include one or more solvents for the functional material. In other embodiments, the liquid comprises a carrier compound for the functional material. In still other embodiments, the liquid comprises two or more solvents, for example a co-solvent mixture, for the functional material. The solvent mixtures can be chosen using various criteria such as the evaporation rate (volatility) of the individual solvents, and the solvating power of the individual solvent components for a particular functional material. Further details of such solvents are provided in paragraph of U.S. Patent Application 2008/0233280 (noted above) that is incorporated herein by reference.

Some particularly useful functional materials include but are not limited to, UV-curable inks, and electrically conductive inks containing electrically conductive particles such as metal flakes or particles. Electrically conductive inks include electrically conductive silver-containing inks, gold-containing inks, copper-containing inks, carbon-containing inks, palladium-containing inks, and inks containing “seed” materials for electroplating or electroless plating. Some of such inks can be obtained commercially from sources such as InkTec (California), Flint Ink Corporation (Michigan), and Method Development Company (Chicago).

Functional material compositions (or “inks”) can comprise functional materials that are dissolved or suspended in suitable solvents as described above and that are known in the art for this purpose. For example, a silver-containing electrically conductive functional material composition (“ink”) can include any useful amount of silver metal particles that are dispersed in aqueous or non-aqueous solvents.

Laser-Engraveable Patternable Elements

The laser-engraveable flexographic printing precursors (some embodiments of laser-engraveable patternable elements) are laser-engraveable to provide a desired relief image, and comprise at least one laser-engraveable layer that is formed from a laser-engraveable composition that comprises three essential components as a thermoplastic elastomeric interpolymer alloy: one or more non-crosslinked halogenated polymers, one or more partially crosslinked polyolefins, and one or more polyesters. These three essential components are described below as well as other optional components, and methods for formulating laser-engraveable layer compositions.

As used in this invention, the term “thermoplastic elastomeric interpolymer alloy” is defined as a mixture of two or more polymers that are not miscible but are compatible and for which the blending of these polymers creates a material that exhibits both thermoplastic properties and elastomeric properties. More precisely, a “thermoplastic elastomeric” is defined as a material, typically a polymer or copolymer, which exhibits both thermoplastic and elastomeric properties.

“Thermoplastic” refers to a polymer that becomes pliable or moldable above a specific temperature, and returns to a solid state upon cooling. “Elastomeric” refers to a polymer that shows elasticity which is a physical property of materials that return to their original shape after the stress that caused their deformation is no longer applied. Thus, thermoplastic elastomers exhibit rubber elasticity at ambient temperature and are fluidized by heating and thus are relatively easy to use in manufacturing, for example, by injection molding and extrusion.

“Interpolymer” indicates that two or more polymers are combined in a mixture to provide the “thermoplastic elastomeric” property.

“Alloy” is defined as a mixture of two or more materials (in this case polymers) in which the components are thermodynamically immiscible but totally compatible with each other and are mixed to create a new material containing multiple phases which exhibits macroscopically uniform physical properties. When a mixture of polymers is not compatible, it has poor physical and mechanical properties. Compatible mixtures show good physical and mechanical properties. Therefore the alloy mixture can be melted and reprocessed without changing the resulting morphology or phase composition of the mixture, or its physical properties. A more detailed description of these terms can be found in Polymer Blends and Composites, J. A. Manson and L. H. Sperling, Plenum Press, NY, 1976.

In general, the thermoplastic elastomeric interpolymer alloy used in the present invention has a softening temperature of less than or equal to 10° C., and typically less than or equal to 0° C., as measured using known procedures including the Vicat method (ASTM-D1525 or ISO 306), differential scanning calorimetry (DSC), dynamic mechanical analysis (DMA, DMTA), or thermal mechanical analysis (TMA).

Non-crosslinked halogenated polymers that are useful in the practice of the present invention include vinyl or vinylidene halide homopolymers or copolymers derived from one or more ethylenically unsaturated polymerizable monomers selected from the group consisting of vinyl esters, acrylonitrile, esters, styrene, acrylates, methacrylates, and vinyl ethers. Preferred polymers include poly(vinyl chloride), poly(vinylidene chloride), poly(vinyl bromide), and poly(vinyl fluoride), poly(vinylidene fluoride), and chlorinated poly(vinyl chloride).

The one or more non-crosslinked halogenated polymers are present in the laser-engraveable layer in a total amount of at least 5 weight % and up to and including 75 weight %, or typically of at least 5 weight % and up to and including 71 weight %, all based on the total dry weight of the laser-engraveable layer.

Useful partially crosslinked polyolefins are copolymers derived from ethylene or propylene with ethylenically unsaturated polymerizable co-monomers selected from classes of esters, vinyl esters, vinyl acrylates and vinyl methacrylates, vinyl acetate, vinyl alkyl ethers, vinyl or vinylidene halides, acrylonitrile, methacrylonitrile, norbornene, α-olefins and vinyl aromatic monomers, which are selected so that the resulting partially crosslinked polyolefin exhibits compatibility with the halogenated polymers described above. Other useful partially crosslinked polyolefins are described in U.S. Pat. No. 4,613,533 (Loomis et al.), U.S. Pat. No. 4,739,012 (Hagman), both incorporated herein by reference. The term “partially crosslinked” refers to a degree of crosslinking that is sufficient to produce an insoluble gel fraction between 5 weight % and 90 weight %.

The one or more partially crosslinked polyolefins are present in the laser-engraveable layer in a total amount of at least 5 weight % and up to and including 90 weight %, and typically at least 20 weight % and up to and including 80 weight %, all based on the total dry weight of the laser-engraveable layer.

In some embodiments, the weight ratio of the non-crosslinked halogenated polymer to the partially crosslinked polyolefin in the laser-engraveable layer is at least 0.05:1 to and including 3:1, or at least 0.2:1 to and including 2:1.

Useful polyesters are typically segmented co-polyesters derived from short or long chain ester units, derived from the reaction of glycols (diols) with dicarboxylic acid chains. Typical long chain glycols are poly(ethylene oxide)glycol, poly(1,2- and 1,3-propylene oxide)glycol, poly(tetramethylene oxide)glycol, random or block copolymers of ethylene oxide and 1,2-propylene oxide, and random or block copolymers of tetrahydrofuran with minor amounts of a second monomer such as 3-methyltetrahydrofuran. Typical short chain glycols include acrylic, alicyclic, and aromatic dihydroxy compounds, usually with molecular weights less than 550. Other useful polyesters are described in U.S. Pat. No. 4,739,012 (Hagman) that is incorporated herein by reference.

The one or more polyesters are present in the laser-engraveable layer in a total amount of at least 5 weight % and up to and including 90 weight %, and typically at least 5 weight % and up to and including 80 weight %, all based on the total dry weight of the laser-engraveable layer.

Other useful constituents of the thermoplastic elastomeric interpolymer alloy and laser-engraveable layer and methods by which they can be prepared are described in more detail in U.S. Pat. No. 4,613,533 (Loomis et al.) and U.S. Pat. No. 4,739,012 (Hagman) that are incorporated herein by reference. Other thermoplastic elastomeric interpolymer alloys useful for this invention are sold under the trade name Alcryn® melt processible rubbers (MPR), examples of which include but are not limited to, Alcryn® 1000 series BK, Alcryn® 2000 series BK (such as Alcryn® 2070BK and Alcryn® 2080BK), Alcryn® 2000 series CL, Alcryn® 2000 series NC, Alcryn® 3000 series NC, Alcryn® 4000 series BK (such as Alcryn® 4670BK), and Alcryn® 4000 series NC.

The laser-engraveable composition or layer can also comprise at least 0.5 weight % and up to and including 35 weight %, or typically at least 5 weight % and up to and including 30 weight %, of one or more near-infrared radiation absorbers (such as a carbon black), based on the total dry laser-engraveable composition or layer weight. The near-infrared (near-IR) radiation absorber is generally uniformly dispersed within the laser-engraveable composition.

In general, the laser-engraveable patternable element used in this invention comprises a laser-engraveable layer that comprises a near-infrared radiation absorber in an amount of at least 0.5 weight %, which near-infrared radiation absorber is a carbon black, carbon nanotubes, an inorganic or organic pigment, an organic dye having at least one absorption peak wavelength of at least 700 nm and to and including 1400 nm, or a combination of any of these materials.

These near-infrared radiation absorbers facilitate or enhance laser engraving, and the near-infrared radiation absorbers have significant (perhaps maximum) absorption at peak wavelengths of at least 700 nm and higher in what is known as the near-infrared and infrared portion of the electromagnetic spectrum. In particularly useful embodiments, the near-infrared radiation absorber has at least one absorption peak λ_(max) in the near-infrared portion of the electromagnetic spectrum of at least 700 nm or at least 800 nm and up to and including 1400 nm. In some embodiments, the near-infrared radiation absorber generally has an essentially panchromic absorption behavior that includes absorption in the near-infrared portion of the electromagnetic spectrum. Mixtures of near-infrared radiation absorbers can be used if desired, and the individual materials can have the same or different absorption spectra. The absorbance of the near-infrared radiation absorber can be matched to the particular laser-engraving radiation that is to be used.

Such near-infrared radiation absorbers can be a carbon black, graphene, carbon nanotubes, an organic or inorganic pigment, or an organic dye having at least one absorption peak wavelength of at least 800 nm, or mixtures or any combination of any of these materials. By “mixture”, it is meant a plurality of each type of infrared radiation absorber. By “combination”, it is meant at least one near-infrared radiation absorber of each type.

It is also possible that the near-infrared radiation absorber can be dispersed non-uniformly within the laser-engraveable layer, and is present in a concentration that is greater near the bottom surface of the laser-engraveable layer than the top surface. Further details of such arrangements are provided in U.S. Pat. No. 8,114,572 (Landry-Coltrain et al.) that is incorporated herein by reference.

Useful near-infrared radiation absorbers can be purchased from various commercial sources such as Cabot Corporation (Boston, Mass.), Orion Engineered Carbons (Kingwood, Tex.), Brewer Science, Inc. (Rolla, Mo.), and Graphene Industries Ltd. (Manchester, UK), or they are prepared using known procedures and commercially available starting materials.

In some embodiments, the laser-engraveable composition or layer can optionally include at least 1 weight % and up to and including 30 weight %, based on the total dry laser-engraveable composition or layer weight, of additional materials selected from the group consisting of hollow, solid, or porous particles, surfactants, plasticizers, lubricants (such as waxes), dyes, microspheres, and additional polymers, or combinations of these materials. Such additional polymers include elastomeric or non-elastomeric resins that are not any of the three essential components described above as forming the thermoplastic elastomeric interpolymer alloy.

For example, the laser-engraveable composition or layer can optionally include organic or inorganic filler materials selected from the group consisting of hollow, solid, or porous particles, surfactants, antioxidants, antiozonants, and microspheres. Useful inorganic fillers and other particles include but not limited to, various aluminas or silicas (treated, fumed, or untreated), calcium carbonate, magnesium oxide, talc, barium sulfate, kaolin, bentonite, hallosite and other clays, zinc oxide, zirconium oxide, mica, titanium dioxide, and mixtures thereof. Particularly useful inorganic fillers are silica, calcium carbonate, and alumina, such as fine particulate silica, fumed silica, porous silica, surface treated silica, sold as Aerosil® from Degussa, Utrasil® from Evonik, and Cab-O-Sil® from Cabot Corporation, micropowders such as amorphous magnesium silicate cosmetic microspheres sold by Cabot and 3M Corporation, calcium carbonate and barium sulfate particles and microparticles, zinc oxide, and titanium dioxide, or mixtures of two or more of these materials.

The laser-engraveable composition or layer can optionally comprise microcapsules that are dispersed generally uniformly within the laser-engraveable composition. These “microcapsules” can also be known as “hollow beads”, “hollow spheres”, “microspheres”, microbubbles”, “micro-balloons”, “porous beads”, or “porous particles”. Some microcapsules include a thermoplastic polymeric outer shell and a core of either air or a volatile liquid such as isopentane or isobutane. The microcapsules can comprise a single center core or many voids (pores) within the core. The voids can be interconnected or non-connected. For example, microcapsules can be designed like those described in U.S. Pat. No. 4,060,032 (Evans) and U.S. Pat. No. 6,989,220 (Kanga), both of which are incorporated herein by reference, in which the shell is composed of a poly[vinylidene-(meth)acrylonitrile] resin or poly(vinylidene chloride), or as plastic micro-balloons as described for example in U.S. Pat. No. 6,090,529 (Gelbart) and U.S. Pat. No. 6,159,659 (Gelbart) that are incorporated herein by reference. Some useful microcapsules are the EXPANCEL® microspheres that are commercially available from Akzo Noble Industries (Duluth, Ga.), Dualite and Micropearl polymeric microspheres that are available from Pierce & Stevens Corporation (Buffalo, N.Y.), hollow plastic pigments that are available from Dow Chemical Company (Midland, Mich.), and the organic porous particles that are described in copending and commonly assigned U.S. Ser. Nos. 13/192,531 and 13/192,533, (both filed Jul. 28, 2011 by Landry-Coltrain and Nair) that are incorporated herein by reference.

Examples of plasticizers can include low molecular weight polyolefins, polyacrylates, polyesters, and fluorinated compounds (other than those described as essential components), silicone compounds, non-crosslinked liquid rubbers and oils, liquid ethylene-propylenes, liquid polybutylene, liquid polypropylene, or mixtures these materials.

Optional resins that can be incorporated in the laser-engraveable compositions or layers include but not limited to, commercial rubbers such as EPDM, SBR, NBR, commercial thermoplastic elastomers, such as Kraton™ SBS, SEBS, SIS products, copolymers of styrene and butadiene, copolymers of isoprene and styrene, styrene-butadiene-styrene block copolymers, styrene-isoprene-styrene copolymers, other polybutadiene or polyisoprene elastomers, nitrile elastomers, polychloroprene, polyisobutylene and other butyl elastomers, elastomers containing chlorosulfonated polyethylene, polysulfide, polyalkylene oxides, or polyphosphazenes, elastomeric polymers of (meth)acrylates, elastomeric polyesters, and other similar polymers known in the art. Still other useful elastomeric resins include vulcanized rubbers, such as Nitrile (Buna-N), Natural rubber, Neoprene or chloroprene rubber, silicone rubber, SBR (styrene-butadiene rubber), NBR (acrylonitrile-butadiene rubber), ethylene-propylene rubber, and butyl rubber. Particularly useful materials of this kind would be used in nano- or micro-particulate form.

Other optional resins are non-elastomeric resins including but not limited to, thermosetting or thermoplastic urethane resins that are derived from the reaction of a polyol (such as polymeric diol or triol) with a polyisocyanate or the reaction of a polyamine with a polyisocyanate, styrenic polymers, acrylate and methacrylate polymers and copolymers, olefinic polymers and copolymers, and epoxide polymers.

The laser-engraveable layer incorporated into the laser-engraveable patternable elements (such as flexographic printing precursors) has a dry thickness of at least 20 μm and up to and including 4,000 μm, or typically of at least 50 μm and up to and including 3,000 μm, or at least 300 μm and up to and including 3,000 μm.

For example, the total dry thickness of the entire laser-engraveable patternable elements, such as flexographic printing plate precursors, is generally at least 150 μm and up to and including 6,000 μm or typically at least 500 μm and up to and including 3,000 μm. Flexographic printing sleeve precursors can generally have a laser-engraveable layer having a dry thickness of at least 2 mm and up to and including 20 mm. Flexographic printing cylinders can have a suitable laser-engraveable layer dry thickness.

Multiple layers can be disposed one on top of the other in order to create a composite laser-engraveable layer. These multiple laser-engraveable layers can be identical in composition or thickness, or they can differ in composition in that they contain differing amounts and types of components (for example, thermoplastic elastomeric interpolymer alloys, near-infrared radiation absorbers, and optional components), or in thickness. For example, a laser-engraveable layer containing hollow microspheres or microbubbles can be disposed under an uppermost laser-engraveable layer that does not contain hollow microspheres. A skilled worker could design many different arrangements of such multiple laser-engraveable layers using the teaching provided herein.

While a single laser-engraveable layer is present in most flexographic printing precursors, there can be multiple laser-engraveable layers formed from the same or different laser-engraveable compositions having the same or different thermoplastic elastomeric interpolymer alloys. Thus, some embodiments comprise two or more layers including at least one laser-engraveable layer according to this invention. For example, there can be an additional or second laser-engraveable layer that is contiguous to a first laser-engraveable layer both of which laser-engraveable layers are prepared according to this invention (comprising the same or different thermoplastic elastomeric interpolymer alloy) and both layers can be laser-engraved at the same or different times.

In other embodiments, a non-laser engraveable layer can be arranged contiguous to a laser-engraveable layer according to the present invention comprising a thermoplastic elastomeric interpolymer alloy.

In still other embodiments, a thermoplastic elastomeric interpolymer alloy-containing laser-engraveable layer can be arranged contiguous to a different laser-engraveable layer that does not contain a thermoplastic elastomeric interpolymer alloy according to the present invention.

Other embodiments include alternating laser-engraveable layers according to this invention and non-laser-engraveable layers, for example such as a sandwich of at least three layers, such as a first laser-engraveable layer according to this invention, a non-laser-engraveable layer, and a second laser-engraveable layer according to this invention. A skilled worker in the art could design any number of alternative arrangements of suitable layers as embodiments of the present invention using the teaching of this disclosure.

In most embodiments, the laser-engraveable layer prepared according to this invention is the outermost layer of the laser-engraveable patternable elements, including embodiments where the laser-engraveable layer is disposed in a flexographic printing plate precursor or on a flexographic printing cylinder precursor as a sleeve. However, in some embodiments, the laser-engraveable layer can be located underneath an outermost capping smoothing layer that provides additional smoothness or different ink reception and release. This smoothing layer can have a general dry thickness of at least 1 μm and up to and including 200 μm.

The laser-engraveable patternable materials can optionally comprise an elastomeric rubber layer that is considered a “compressible” layer (also known as a cushioning layer) and is disposed over the substrate and under a laser-engraveable layer according to this invention. In most embodiments, the compressible layer is disposed directly on the substrate and the laser-engraveable layer is disposed directly on the compressible layer. While the compressible layer can be non-laser-engraveable, in some embodiments, the compressible layer comprises one or more components that also make it laser-engraveable (although not necessarily a thermoplastic elastomeric interpolymer alloy).

The compressible layer can also have microvoids or microspheres that are dispersed within the one or more elastomeric rubbers. Useful microspheres are described above as “microcapsules”, “hollow beads”, “hollow spheres”, microbubbles”, “micro-balloons”, “porous beads”, or “porous particles”, which are dispersed (generally uniformly) within the one or more elastomeric rubbers in the compressible layer. The compressible layer can also comprise other addenda such as filler materials and addenda described above for the laser-engraveable layer.

The dry thickness of the compressible layer is generally at least 50 μm and up to and including 4,000 μm, or typically at least 100 μm and up to and including 2,000 μm.

The laser-engraveable patternable elements (such as laser-engraveable flexographic printing precursors) can have a suitable dimensionally stable, non-laser-engraveable substrate having an imaging side and a non-imaging side. The substrate has at least one laser-engraveable layer disposed over it on its imaging side. Suitable substrates include dimensionally stable polymeric films, high temperature polymeric films, chemically resistant films, aluminum sheets or cylinders, transparent foams, ceramics, glasses, porous glasses, fabrics, laminates of polymeric films (from condensation or addition polymers) and metal sheets such as a laminate of a polyester and aluminum sheet, polyester/polyamide laminates, or a laminate of a polyester film and a compliant or adhesive support. Polyester, polycarbonate, poly(vinyl chloride), and polystyrene films are typically used. Useful polyester substrates include but are not limited to films of poly(ethylene terephthalate) and poly(ethylene naphthalate). Other high temperature polymers useful as high temperature substrates include but are not limited to, polyetherimides, polyimides (such as Kapton™ films), poly(etheretherketone) (PEEK), polysulfone, polyethersulfone, polyphenylsulfone, and polyphenylenesulfide.

The substrate can have any suitable dry thickness, but generally it has a dry thickness of at least 0.01 mm or at least 0.05 mm and up to and including 5 mm.

Some other particularly useful substrates comprise one or more layers of a metal, fabric, or polymeric film, glass, porous glass, or ceramic used in combination. For example, a fabric web can be applied to a polyester or aluminum support using a suitable adhesive. For example, a fabric web can have a thickness of at least 0.1 mm and up to and including 0.5 mm, and the polyester support thickness can be at least 100 μm and up to and including 200 μm or the aluminum support can have a thickness of at least 200 μm and up to and including 400 μm. For example, a glass substrate can have a thickness of at least 100 μm and up to and including 5 mm. The dry adhesive thickness can be at least 10 μm and up to and including 300 μm.

A thin conductive layer or film of, for example, poly(3,4-ethylenedioxythiophene) (PEDOT), polyacetylene, polyaniline, polypyrrole, or other polythiophenes, indium tin oxide (ITO), or graphene, can be disposed between the substrate and a laser engraveable layer.

There can be a non-laser-engraveable backcoat on the non-imaging side of the substrate that can comprise a soft rubber or foam, or other compliant layer. This non-laser-engraveable backcoat can provide adhesion between the substrate and printing press rollers and can also provide extra compliance to the resulting laser-engraved patterned member, or for example to reduce or control the curl of a resulting laser-engraved patterned member. Alternatively, this backcoat can be laser-engraveable so as to provide the capability for writing specific information, product identification, classification, or other metadata on the backside while a relief image is on the imaging (imaged) side.

The laser engraveable patternable element (such as a laser-engraveable flexographic printing precursor) can be subjected to mechanical grinding by known methods in the art using commercially available machines such as belt grinders or cylindrical grinders using an abrasive wheel or abrasive paper. Grinding can be done on either the top surface of the imaging side of the patternable material or the bottom surface thereof, prior to the optional introduction of a support, in order to ensure thickness uniformity, or it can be done on the laser-engraveable layer surface to achieve a desired surface roughness that will improve ink wetting or transfer.

Preparation of Laser-Engraveable Patternable Elements

Preparation of the laser-engraveable patternable elements used in the present invention is illustrated as follows with respect to laser-engraveable flexographic printing precursors but other laser-engraveable patternable elements within the scope of this invention can be similarly prepared.

The laser-engraveable composition can be prepared by melt-blending or melt-mixing the components used therein using any suitable mechanical mixing device known in the industry, such as for example a screw extruder, a Brabender mixer, a 2-roll or a 3-roll mill. Preferably, the polyolefin and the non-crosslinked halogenated polymer are initially mixed in the presence of a crosslinking agent specific to cause the partial crosslinking of the polyolefin, followed by mixing with the polyester. Alternately, the polyolefin can be crosslinked with a suitable crosslinking agent or irradiation prior to mixing with the halogenated polymer, and the polyester.

Suitable thermal crosslinking conditions can be used as one skilled in the art would know from the specific choice of the chemical crosslinking agent. For example, thermal curing can be achieved using infrared radiation or heating in an oven, a rotocure unit, in-line heating device, or a compounder or extruder. Various curing additives and accelerators can also be added to aid the partially crosslinking of the polyolefin. Other known crosslinking methods include, for example, electron beam irradiation and gamma irradiation.

The continuous laser-engraveable layer (for example, on a fabric web with the compressible layer) can then be laminated (or adhered) to a suitable substrate such as a polymeric film such as a polyester film to provide the laser-engraveable layer on a substrate, for example, a fabric web adhered with an adhesive to the polyester film. The continuous laser-engraveable layer can be ground using a suitable grinding apparatus to provide a uniform smoothness and thickness in the continuous laser-engraveable layer. The smooth, uniformly thick laser-engraveable layer can then be cut to a desired size to provide suitable laser-engraveable patternable elements useful in this invention, such as laser-engraveable flexographic printing precursors.

The process for making laser-engraveable flexographic printing sleeves is similar but the compounded laser-engraveable layer composition can be applied or deposited around a printing sleeve core, and cooled to form a continuous cylindrical laser-engraveable flexographic printing sleeve precursor.

Similarly, a continuous calendered laser-engraveable layer on a fabric web can be deposited around a printing cylinder and cooled to form a continuous flexographic printing cylinder precursor.

This process can be repeated as many times as desired to form two or more laser-engraveable layers over the substrate, which laser-engraveable layers can be contiguous, or any two laser-engraveable layers according to this invention can be separated by intermediate layers that are either laser-engraveable or non-laser-engraveable, but which intermediate layers do not contain a thermoplastic elastomeric interpolymer alloy.

Surface Patterning Prior to Imaging

It is generally recognized that laser engraveable patternable element that are prepared using vulcanized rubbers require a surface grinding step during manufacturing of such elements. Surface grinding provides two advantages. The first is that it provides control over the element thickness and thickness uniformity. The second is that it provides a controlled surface roughness that enhances the printing or patterning quality of the element with functional materials. Although this grinding step can be included in the manufacturing workflow for the laser-engraveable patternable element, it has several disadvantages. It only provides a random surface structure. Control of the surface quality during grinding can be difficult. Extreme amounts of dirt from the ground surface can be generated and this can contaminate the laser-engraveable patternable element or other products in the plant. The rubber, which is elastomeric, must be attached to a non-elastic support that will provide mechanical stability during the grinding process. In addition, uncured, non-crosslinked, or un-vulcanized laser-engraveable patternable elements cannot be successfully ground since these materials are too soft and will be deformed during the process, particularly since heat is generated at the interface between the grinding media and the element during the grinding process.

It is also known that (U.S. Patent Application Publication 2010/0143841 of Stolt et al.) that providing a laser-engraveable patternable element with a specified surface micro-pattern can result in improved printing quality compared to that obtained with a smooth surface. However, the method used to create the patterned areas involved exposing the photopolymer to radiation through an image mask to cause crosslinking in the exposed areas.

The topmost surface of the laser-engraveable layer used in this invention cannot be readily roughened by grinding, nor patterned by photoimaging through a mask. Useful methods for controlling the topmost surface are direct laser ablation or surface embossing. These methods can be used to provide a specified roughness or to provide a micropattern on the topmost surface of a laser-engraveable patternable element.

A predetermined pattern can be laser-engraved (or imaged) into the topmost surface of the laser-engraveable patternable element described herein using high resolution laser engravers, such as that described for LES2 (described below).

Embossing the topmost surface of the laser-engraveable patternable element can be performed by any method known in the art. For example, the laser-engraveable patternable element can be fed between 2 cylinders, where the cylinder that contacts the topmost surface has been pre-patterned or pre-embossed using any method known in the art, such as using a diamond stylus, a laser engraving, or a chemical etch. Heat and pressure of this assembly can be controlled so that only the topmost surface of the laser-engraveable layer softens and replicates the exact features (peaks and valleys) of the pre-engraved or pre-embossed surface without causing melting and flowing of the laser-engraveable layer that would alter its macroscopic shape or dimension. Other methods include placing a pre-patterned film, element, matte film, roughened, ground, or etched metal surface, or a stamp, against the topmost surface of the laser-engraveable layer and subjecting this assembly to heat and pressure in a mold, a molding press, or conveying it (roll-to-roll) through heated rollers or a laminator. The assembly is then cooled down to allow the laser-engraveable layer to solidify, and the laser-engraveable layer is removed from the mold, providing a patterned, laser-engraveable surface. This can be performed while the laser-engraveable patternable element is being shaped into a desirable form or in a subsequent step.

Useful resulting patterns on the laser-engraveable patternable element are checkerboard or repeat patterns with square, rectangular, circular, or oblong top shapes in the raised features. These raised shapes can have heights of at least 1 μm to and including 20 μm, or at least 1 μm to and including 15 μm, or more likely at least 1 μm to and including 5 μm. The raised shape height is defined as the difference between the topmost surface and the bottom of the valleys between the patterned features of the laser-engraveable patternable element. Useful lateral dimensions of these surface features are at least 1 μm to and including 30 μm wide and at least 1 μm to and including 30 μm long, or at least 1 μm to and including 10 μm wide and 1 μm to 10 μm long. The repeat distance of the pattern can be at a higher frequency than that of the final relief image that will be engraved, with spacing (peak-to-peak) of at least 5 μm to and including 50 μm, or at least 5 μm to and including 35 μm. Additional patterns are described in U.S. Patent Application Publication 2010/0143841 (Stolt et al.) that is incorporated herein by reference.

In some embodiments, the laser-engraveable patternable element has an uppermost surface having a relief pattern with a relief image that has a depth of less than 10 μm and a repeat length in both horizontal directions of less than 20 μm.

Laser-Engraving for Imaging

Laser engraving can be accomplished using a near-IR radiation emitting diode or carbon dioxide or Nd:YAG laser. It is desired to laser engrave the one or more laser-engraveable layers in the laser-engraveable patternable element to provide a relief image with a minimum relief image depth of at least 10 μm and up to and including 4,000 μm, or of at least 50 μm and up to and including 1,000 μm. For laser-engraveable flexographic printing members, more likely, the minimum relief image depth is at least 300 μm and up to and including 4,000 μm or up to and including 1,000 μm being more desirable. “Relief floor depth” is defined as the difference measured between the floor (lowest laser-engraved areas) of the laser-engraved patterned element and its outermost printing surface. It is to be understood that the relief image depth between image features (relief image depth, which is defined as the difference measured between the bottom of a specific laser-engraved area and its outermost printing surface) that are closely spaced will be less than the relief floor depth. The floor of the relief image can be the substrate if all layers are completely removed in the imaged regions.

A semiconductor near-infrared radiation laser or one or more (array) of such lasers operating at a wavelength of at least 700 nm and up to and including 1400 nm can be used, and a diode laser operating at from at least 800 nm and up to and including 1250 nm is particularly useful for laser-engraving. Imagewise exposing can also be carried out using one or more near-infrared radiation emitting lasers and the laser-engraveable layer can for example, comprise a near-infrared radiation absorber such as a carbon black.

Generally, laser-engraving is achieved using at least one near-infrared radiation laser having a minimum fluence level of at least 1 J/cm² at the element topmost and typically near-infrared imaging fluence is at least 10 J/cm² and up to and including 1,000 J/cm² or typically at least 50 J/cm² and up to and including 800 J/cm². For example, laser-engraving can be carried out using a diode laser, an array of diode lasers connected with fiber optics, a Nd-YAG laser, a fiber laser, a carbon dioxide gas laser, or a semiconductor laser. Such instruments and conditions for their use are well known in the art and readily available from a number of commercial sources. Detailed descriptions of such imaging apparatus and methods can be found in U.S. Patent Application Publications 2010/0068470A1 (Sugasaki), 2008/018943A1 (Eyal et al.), and 2011/0014573A1 (Matzner et al.), all of which are hereby incorporated by reference.

A suitable laser engraver that would provide satisfactory engraving is also described in WO 2007/149208 (Eyal et al.) that is incorporated herein by reference. This laser engraver is considered to be a “high powered” laser ablating imager or engraver and has at least two laser diodes emitting radiation in one or more near-infrared radiation wavelengths so that imaging with the one or more near-infrared radiation wavelengths is carried out at the same or different depths relative to the outer surface of the laser-engraveable layer. For example, the multi-beam optical head described in the noted publication incorporates numerous laser diodes, each laser diode having a power in the order of at least 5-10 Watts per emitter width of 100 μm. These lasers can be modulated directly at relatively high frequencies without the need for external modulators.

Thus, laser-engraving (laser imaging) can be carried out at the same or different relief image depths relative to the outer surface of the laser-engraveable layer using two or more laser diodes, each laser diode emitting near-infrared radiation in one or more wavelengths.

Other imaging (or engraving) devices and components thereof and methods are described for example in U.S. Patent Application Publications 2008/0153038 (Siman-Tov et al.) describing a hybrid optical head for direct engraving, 2008/0305436 (Shishkin) describing a method of imaging one or more graphical pieces in a flexographic printing plate precursor on a drum, 2009/0057268 (Aviel) describing imaging devices with at least two laser sources and mirrors or prisms put in front of the laser sources to alter the optical laser paths, and 2009/0101034 (Avid) describing an apparatus for providing an uniform imaging surface, all of which publications are incorporated herein by reference. In addition, U.S. Patent Application Publication 2011/0014573 (Matzner et al.) describes an engraving system including an optical imaging head, a printing plate construction, and a source of imaging near-infrared radiation, which publication is incorporated herein by reference. U.S. Patent Application Publication 2011/0058010 (Aviel et al.) describes an imaging head for 3D imaging of flexographic printing plate precursors using multiple lasers, which publication is also incorporated herein by reference.

The one or more laser-engraving radiation sources can be selected from the group consisting of laser diodes, multi-emitter laser diodes, laser bars, laser stacks, fiber lasers, and a combination thereof. In particular embodiments, the laser-engraveable layer of the precursor comprises an infrared radiation absorber and the one or more laser-engraving radiation sources provide infrared radiation.

Other systems for providing relief images by laser-engraving are described for example in U.S. Pat. No. 6,150,629 (Sievers) and U.S. Pat. No. 6,857,365 (Juffinger et al.) and in U.S. Patent Application Publications 2006/0132592 (Sievers), 2006/0065147 (Ogawa), 2006/0203861 (Ogawa), and 2008/0153038 (noted above), 2008/018943A1 (noted above), and 2011/0014573A1 (noted above).

During imaging, products from the laser-engraving can be gaseous or volatile and readily collected by vacuum for disposal or chemical treatment. Any solid debris from engraving can be collected and removed using suitable means such as vacuum, compressed air, brushing with brushes, rinsing with water, blotting with an absorbent material, ultrasound, or any combination of these.

During printing of a pattern of a functional material, the laser-engraved patterned element is typically “inked” using known methods (more details below) and the functional material is appropriately transferred to a suitable receiver element composed of a paper, plastic, fabric, paperboard, metal, particle board, wall board, glass, flexible glass, glass-coated substrate, ceramic, or cardboard.

After this printing operation, the laser-engraved patterned element can be cleaned and reused in a suitable manner as many times as necessary. Cleaning can be accomplished with compressed air, water, or a suitable aqueous or organic solution, or by rubbing with cleaning brushes or pads. Surfactants or soaps can be added to the aqueous or organic solutions to accelerate cleaning.

For example, flexographic printing of a functional material can be used for printing a pattern on a variety of soft or easily deformed materials including but not limited to, paper, paperboard stock, corrugated board, polymeric films, fabrics, metal foils, glass, glass-coated materials, flexible glass materials, and laminates or multiple materials.

Recycling Processes

Defective or used laser-engraveable patternable elements or laser-engraved patterned elements described herein can be recycled for further use. Such as a method for recycling can comprise:

melting a laser-engraveable layer of a laser-engraveable patternable material or a laser-engraved layer of a laser-engraved patterned member, the laser-engraveable layer or laser-engraved layer comprising a thermoplastic elastomeric interpolymer alloy that comprises:

a non-crosslinked halogenated polymer,

a partially crosslinked polyolefin, and

a polyester,

to form a melt, and

reforming the melt into a new laser-engraveable patternable material.

Before or after printing or other use of the laser-engraved patterned element, it can be cleaned and reused by recycling the laser-engraveable layer (before imaging) or laser-engraved layer (after imaging). For example, a laser-engraveable layer can be melted and recycled before it is engraved if there is an undesirable defect in the layer. Alternatively, it can be recycled after laser-engraving but before printing if the laser-engraving process creates an error or if there is a need for correction in the image. Lastly, the laser-engraved layer can be recycled after a printing run is finished. Before melting, the laser-engraveable layer or laser-engraved layer can be separated from all other layers and any substrate present in the laser-engraveable patternable element or laser-engraved patterned element.

Equipment that can be used to effect the steps of the recycling method described above include, but are not limited to, single-screw extruders, twin-screw extruders, extruders equipped with dies, Brabender compounders, injection molders, calendering units, single or twin screw augers, compounding extrusion units, pelletizing units, sheet extrusion units, chopping and regrinding units.

Printing Processes

The method of this invention uses the laser-engraved patterned element described herein to print a suitable pattern of a functional material to a receiver element. The present invention enables printing of a variety of functional materials over relatively large areas with desirable resolution (for example, less than 20 μm or even less than 10 μm). In some embodiments, where the functional material is an electrically conductive functional material, the resolution can be as low as 1 to 5 μm. The method also provides a means for printing of sequential overlays without hindering the utility of one or more underlying layers. The method can be adapted to high-speed production processes for the fabrication of electronic devices and components.

Compositions of the functional material can be provided on the relief image of the laser-engraved patterned element by applying it to the raised surface of the relief image. The functional material composition can be applied at any time after the laser-engraved patterned element is formed, for example within 24 hours, or even within 12 hours, or within as little as 10 minutes. The functional material composition can be applied by any suitable method, including the use of an anilox roller.

In one embodiment, the functional material composition is applied to the laser-engraved patterned element and forms a layer on the relief image on the element, that is, the composition forms a layer on the raised surface of the relief image. The functional material composition can be formed as a continuous or discontinuous layer. The thickness of the functional material composition on the relief image is not particularly limited. In one embodiment, the composition thickness is typically less than the relief image height (that is, the difference between the raised surface and the recessed surface) of the laser-engraved patterned element.

The functional material composition should be capable of forming a layer on at least the raised surface of the relief image. Beyond the elastomeric modulus of the laser-engraved layer, certain other properties such as the solvent resistance of the laser-engraved patterned element, the boiling point of the solvent(s) in the functional material composition and the solubility of the functional material in the solvent(s), can influence the capability of a certain functional material to form a layer and be transferred as a pattern to a receiver element. It is well within the understanding of a skilled worker in the art to determine the appropriate combination of functional material, composition solvent(s), and laser-engraveable layer composition.

After the functional material composition has been applied to at least the raised surface of the relief image of the laser-engraved patterned element. The liquid of the functional material composition can be removed sufficiently to form a film of the functional material on at least the raised surface of the relief image. Liquid removal can be achieved in any manner, for example using gas jets, blotting with an absorbent material, evaporation at room temperature or an elevated temperature, or other means known in the art. In one embodiment, the liquid can be removed by drying during the application of the functional material to the relief image. Effective drying can be assisted by selecting a solvent(s) for the functional material that has a relatively low boiling point or by application of a very thin layer (for example, less than 1 μm) of the functional material composition. The liquid can be removed sufficiently to provide a pattern of the functional material corresponding to the relief image, to the receiver element. In one embodiment, a film of the functional material on the laser-engraved patterned element has a thickness of at least 0.001 μm to and including 2 μm. In other embodiments, the film layer of functional material on the laser-engraved pattern element has a thickness of at least 0.1 μm to and including 1 μm.

In some embodiments, the functional material is substantially free of liquid (solvent or carrier), to form a film on the relief image. In other embodiments, the liquid is substantially removed from the functional material composition to form a dried film of functional material on at least the raised surface of the relief image, and the dried film is exposed to a compound in its vaporized state in order to enhance transfer to a receiver element. The vaporized compound is not limited and can include water vapor or the vapor of an organic compound. Although not limited to the following explanation, it is contemplated that the exposure of the dried film of functional material to the vaporized compound plasticizes the dried film to the extent that the film becomes slightly more malleable and increases the capability of the functional material to adhere to the receiver element.

In still another embodiment of the present invention, the laser-engraveable patternable element can be used to form a pattern of a mask material on a receiver element. In this embodiment, the mask material can be considered as a functional material. That is, the mask material can be applied on at least the raised surface of the relief image and transferred to a receiver element to form a pattern. The mask material should at least have the same capabilities as described above for a functional material, with the exception that the mask material does not facilitate an operation as an active material or an inactive material in a variety of components and devices. In some embodiments, the recessed surfaces of the relief image represent the pattern of the functional material that will be ultimately be formed on the receiver element, and the raised surface forming the pattern of the mask material on the receiver element represent the background or featureless areas on the receiver element. The pattern of the mask material on the receiver element is the opposite or the negative of the pattern of functional material desired for the electronic component or device. The pattern of the mask material on the receiver element correspondingly forms a pattern on the surface of the receiver element. Functional material that does facilitate an operation as an active or an inactive material in a variety of components and devices as described above can be applied to at least pattern or open areas on the receiver element. Subsequent to the application of the functional material, the mask material is optionally removed. In another mask embodiment, the raised surfaces of the relief image represent the pattern of the functional material that will be ultimately be formed on the receiver element. Materials suitable as a mask material are not limited provided that the mask material is capable of (1) forming a layer on at least the raised surface of the relief image of the laser-engraved patterned element, (2) transferring a pattern according to the relief image to the receiver element, and optionally (3) removing the pattern of functional material from the receiver element without damaging the functional material.

In general, transferring the functional material from the raised surface of a relief image to a receiver element creates a pattern of the functional material on the receiver element. The transferring can be referred to as “printing”. Contacting the functional material on the raised surface to the receiver element transfers the functional material, such that the pattern of functional material forms when the laser-engraved patterned element is separated from the receiver element. In one embodiment, all or substantially all of the functional material positioned on the raised surface transfer to the receiver element. Separation of the laser-engraved patterned element from the receiver element can be accomplished using any suitable means including but not limited to, peeling, gas jets, liquid jets, or mechanical devices.

Optionally, pressure can be applied to the laser-engraved patterned element to assure contact and complete transfer of the functional material to the receiver element. Functional material transfer can be accomplished in any manner. For example, transfer can be carried out by moving the raised surface of the relief image to the receiver element, by moving the receiver element to the raised surface of the relief image, or by moving both into contact with each other. In one embodiment, the functional material is transferred manually. In another embodiment, the transfer of the functional material is automated such as by example, by a conveyor belt, reel-to-reel process, directly driven moving fixtures, chain, belt, or gear-driven fixtures, frictional roller, printing press, or rotary apparatus. The thickness of the layer of functional material is not particularly limited with a typical thickness of the layer of functional material on the receiver element being at least 1 nm to and including 1000 nm.

While a particularly useful method of applying the functional material composition to a receiver element is the use of flexography and a patterned flexographic printing member, the functional material composition can also be applied to a receiver element using gravure or intaglio printing members and printing methods.

The method of this invention can be carried out at room temperature such as at least 17° C. to and including 30° C. but is not so limited, and can be carried out at a lower temperature down to about 5° C., or at an elevated temperature up to 100° C. provided that the heat does not harm the laser-engraveable patterned element, the functional material, the receiver element, or their ability to form a pattern on the receiver element.

Printed patterns of functional materials can be used in various industries to provide images, dots, text, and patterns of lines, shapes, or areas.

A functional material composition can be applied to the receiver element surface using any suitable laser-engraved patterned element described herein. In some embodiments, the method of this invention can be used to provide a printed pattern comprising lines having an average line width of less than 20 μm, or typically fine lines having an average line width of less than 15 μm and generally at least 3 μm. These average values can be determined by measuring the line width in randomly selected locations in images captured from optical micrographs of appropriate magnification.

In some of the embodiments, the method of this invention provides a printed pattern of fine lines containing a seed material for a subsequent electroless plating process. For example, for copper electroless plating, such seed materials include but are not limited to, metals such as palladium, tin, and silver, or a mixture of tin and palladium.

In other embodiments, the method of this invention can be used to provide a pattern of fine lines having an electrical conductivity that is high enough for a subsequent electroplating process. Such an electrical conductivity is at least 0.1 S/cm and the details of such processes are known in the art.

In still other embodiments, the method of this invention can be used to provide a pattern of fine lines composed of a functional material composition that is formulated to protect an underlying uniform metal film during a subsequent etching process. For example, the functional material composition can be formulated to protect an underlying copper or silver film during a subsequent etching process.

The laser-engraved patterned element used in this invention can have a relief image in the laser-engraved layer(s) comprising a predetermined pattern of relief lines, each line having an average width of at least 1 μm and up to and including 10 mm. Such lines can also have an average height of at least 10 μm and up to and including 4,000 μm. These average dimensions can be determined by measuring the lines in at least 10 places and determining the width or height using known image analysis tools including but not limited to, profilometry, optical microscopic techniques, atomic force microscopy, and scanning electron microscopy.

The receiver element can be composed of any suitable material including but are not limited to, polymeric films, metals, silicon or ceramics, fabrics, papers, and combinations thereof provided that a pattern of a functional material can be formed thereon. The receiver element can be transparent or opaque, and rigid or flexible. The receiver element can include one or more layers or one or more patterns of other materials before the pattern of functional material is applied according to the present invention. The surface of the receiver element can be treated for example with a primer layer, to promote adhesion of the functional material or to promote adhesion of a separate adhesive layer on a receiver element substrate. An adhesive layer can be disposed on a substrate in the receiver element and this adhesive layer can have various properties in response to heat (thermally activatable) that aids in the adhesion of the pattern of functional material. Useful adhesive materials of this type are described for example in [0057] of U.S. Patent Application 2008/0233280 (noted above).

The substrates can be surface-treated by exposure to corona discharge, mechanical abrasion, flame treatments, or oxygen plasmas, or by coating with various polymeric films, such as poly(vinylidene chloride) or an aromatic polysiloxane as described for example in U.S. Pat. No. 5,492,730 (Balaba et al.) and U.S. Pat. No. 5,527,562 (Balaba et al.) and U.S. Patent Application Publication 2009/0076217 (Gommans et al.).

Suitable substrates in the receiver elements include but are not limited to, metallic films or foils, metallic films on polymer, glass, or ceramic supports, metallic films on electrically conductive film supports, semi-conducting organic or inorganic films, or organic or inorganic dielectric films. For example, useful substrates can include indium-tin oxide coated glass, indium-tin oxide coated polymeric films, poly(ethylene terephthalate) films, poly(ethylene naphthalate) films, polyimide films, polycarbonate films, polyacrylate films, polystyrene films, polyolefin films, polyamide films, silicon, metal foils, cellulosic papers or resin-coated or glass-coated papers, glass or glass-containing composites, ceramics, metals such as aluminum, tin, and copper, and metalized films. The receiver element substrate can also include one or more charge injection layers, charge transporting layers, and semi-conducting layers on which the functional material pattern is formed.

Particularly useful substrates are polyesters such as poly(ethylene terephthalate), polycarbonate, or poly(vinylidene chloride) films that have been surface-treated as noted above.

After the pattern of functional material has been applied to the receiver element in a suitable manner, the pattern can be further treated if desired using heat or exposure to actinic radiation (such as UV, visible, or IR radiation). For example, if the functional material contains metal nanoparticles, the pattern of functional material can be heated to sinter the particles and render pattern lines conductive. Sintering forms a coherent bonded mass by heating a metal powder in the form of metal nanoparticles, without melting. Sintering can be carried out using temperatures and conditions that would be apparent to one skilled in the art.

The present invention provides at least the following embodiments and combinations thereof, but other combinations of features are considered to be within the present invention as a skilled artisan would appreciate from the teaching of this disclosure:

1. A method for providing a pattern of a functional material, the method comprising:

imagewise exposing a laser-engraveable patternable element that comprises at least one laser-engraveable layer comprising a thermoplastic elastomeric interpolymer alloy that comprises:

a non-crosslinked halogenated polymer,

a partially crosslinked polyolefin, and

a polyester,

to laser-engraving radiation to provide a directly laser-engraved patterned element having a relief image in the laser-engraveable layer, and

using the directly laser-engraved patterned element to print a pattern of a functional material.

2. The method of embodiment 1, wherein the laser-engraveable patternable element is a flexographic printing precursor and the relief image in the laser-engraveable layer has a minimum relief image depth of at least 30 μm.

3. The method of embodiment 1, wherein the laser-engraveable patternable element is a gravure or intaglio printing precursor and the relief image is the laser-engraveable layer has a minimum relief image depth of at least 10 μm.

4. The method of any of embodiments 1 to 3, comprising imagewise exposing using one or more near-infrared radiation emitting lasers and the laser-engraveable layer further comprises a near-infrared radiation absorber in an amount of at least 0.5 weight %.

5. The method of any of embodiments 1 to 4, comprising:

applying a functional material to a raised surface of the directly laser-engraved patterned element having a relief image that has a minimum relief image depth of at least 10 pin, to form a film of the functional material on the raised surface of the relief image, and

contacting the film of the functional material with a receiver element to form a pattern of the functional material on the receiver element that corresponds to the relief image.

6. The method of any of embodiments 1 to 5, comprising:

using the laser-engraved patterned element to print a pattern with a functional material comprising nanoparticles of an electrically conductive material selected from the group consisting of silver, gold, copper, palladium, indium-tin oxide, and combinations thereof.

7. The method of any of embodiments 1 to 6, wherein the functional material is selected from the group consisting of electrically conductive materials, semi-conductive materials, dielectric materials, small molecule materials, polymeric materials, bio-based materials, and combinations thereof.

8. The method of any of embodiments 1 to 7, wherein the non-crosslinked halogenated polymer is present in the laser-engraveable layer in an amount of at least 5 weight % and up to and including 75 weight %, based on the total dry weight of the laser-engraveable layer.

9. The method of any of embodiments 1 to 8, wherein the partially crosslinked polyolefin is present in the laser-engraveable layer in an amount of at least 5 weight % and up to and including 90 weight %, based on the total dry weight of the laser-engraveable layer.

10. The method of any of embodiments 1 to 9, wherein the polyester is present in the laser-engraveable layer in an amount of at least 5 weight % and up to and including 90 weight %, based on the total dry weight of the laser-engraveable layer.

11. The method of any of embodiments 1 to 10, wherein the thermoplastic elastomeric interpolymer alloy has a softening temperature of less than or equal to 10° C.

12. The method of any of embodiments 1 to 11, wherein the laser-engraveable layer further comprises a near-infrared radiation absorber in an amount of at least 0.5 weight %, which near-infrared radiation absorber is a carbon black, carbon nanotubes, an inorganic or organic pigment, an organic dye having at least one absorption peak wavelength of at least 700 nm to and including 1400 nm, or a combination of any of these materials.

13. The method of any of embodiments 1 to 12, wherein the laser-engraveable patternable element comprises multiple layers including at least one laser-engraveable layer.

14. The method of any of embodiments 1 to 13, wherein the laser-engraveable patternable element further comprises a substrate over which the laser-engraveable layer is disposed.

15. The method of any of embodiments 1 to 14 for providing a pattern comprising lines having an average line width of less than 20 μm.

16. The method of any of embodiments 1 to 15 for providing a pattern of functional material that comprises a seed material for a subsequent plating process.

17. The method of any of embodiments 1 to 16 for providing a pattern of functional material that is formulated to protect an underlying uniform metal film during a subsequent etching process.

18. The method of any of embodiments 1 to 17, comprising using the directly laser-engraved patterned element to print a pattern of a functional material onto a substrate or a layer on a substrate.

19. The method of embodiment 18, wherein the pattern of a functional material is printed onto a primer layer, adhesive layer, charge injection layer, charge transporting layer, or semiconducting layer on a substrate.

20. An element having a printed pattern of a functional material, which is obtained from the method of any of embodiments 1 to 19.

The following Examples are provided to illustrate the practice of this invention and are not meant to be limiting in any manner.

Laser Engraving Systems:

Laser Engraving System LES1:

A first engraving system included using a 5.3 watt, 1064 nm pulsed single mode ytterbium fiber laser with an 80 μm spot size. The pulse width was approximately 30 nsec and the pulse repetition rate was 20 kHz. The image contained 1 cm×1 cm patches that were rastered at 800 dpi using laser beam speeds of from 13 to 6.5 inch/sec (33.02 to 16.5 cm/sec) resulting in corresponding fluences of from 51 J/cm² to 102 J/cm². The depths of the ablated patches were measured using a self non-rotating spindle using a ratchet stop micrometer. The quality of the imaged features, presence of melt edges, and the amount and severity of redeposition of the ablation debris were determined visually and using an optical microscopy and scanning electron microscopy (SEM).

Laser Engraving System LES2:

A second engraving system included using a continuous wave (CW) laser operating in the 830 nm range at 25 Watts in 960 channels. The laser beam has a 3 μm spot size (Kodak SQUAREspot® technology) at optimum focus. The sample was mounted on flat plate that moves in the Y (fast scan) direction while the laser head moves on an air bearing in the X (slow scan) direction. Pixel placement was on 2 μm centers corresponding to an addressability of 12,800 dpi. The ablation sensitivity value for the plate material was calculated by dividing the combined fluence for the 3 sequential engraving passes by the measured relief (in μm) that resulted from these engravings. When imaging at 0.2 msec, this fluence was calculated to be 19.7 J/cm² for the sum of the 3 passes. Unless other specified, these were the conditions used in the examples below. The resulting relief image after engraving was evaluated using the Tencor P10 Surface Profilometer. The quality of the imaged features, presence of melt edges, and the amount and severity of redeposition of the ablation debris were determined visually and using an optical microscopy and scanning electron microscopy (SEM).

Laser Engraving System LES3:

A third engraving system included using a multiplicity of fiber-coupled laser diodes (approximately 10 Watts each) emitting at about 915 nm to engrave a sample assembly that was mounted onto a rotating drum at a resolution of 150 lpi (lines per inch, or 381 lines per cm). The quality of the imaged features, presence of melt edges, and the amount and severity of redeposition of the ablation debris were determined visually and using an optical microscopy and scanning electron microscopy (SEM).

Invention Example IE1

Thermoplastic elastomeric interpolymer alloy pellets (3.5 g, Alcryn® 2070BK containing 7 weight % of carbon black and 39 weight % of chlorine from Advanced Polymer Alloys) were introduced into an aluminum mold with a sheet of 300FN Kapton™ on one side for ease of release, and were pressed into the shape of a flat plate using a Carver press (model #3393) set at 3000 lbs (1360.8 kg) at 190° C. for 5 minutes. The assembly of the mold and its contents were removed and then cold-pressed in another Carver press that was set at 3000 lbs (1360.8 kg) with no heating for 30 minutes. The resulting laser-engraveable flexographic printing precursor (or laser-engraveable patternable element) was 75×75 mm in size and approximately 0.8 mm thick. This precursor was laser engraved using LES1 and the relief image depth obtained at the laser fluence of 102 J/cm² was 227 μm. The precursor was further laser engraved using LES2 (at the stated fluence of 19.7 J/cm²] and the relief image depth laser was determined to be 48 μm. The edges of the laser engraved features were sharp, showing no melt edges and the laser engraved flexographic printing member was very clean, showing no redeposition of ablation debris sticking to the laser engraved relief image.

Invention Example IE2

Thermoplastic elastomeric interpolymer alloy pellets (Alcryn® 4670BK containing 0.5 weight % of carbon black and 35 weight % of chlorine from Advanced Polymer Alloys) were introduced into an aluminum mold with a sheet of 300FN Kapton™ on one side for ease of release, and were pressed into the shape of a flat plate using a Carver press (model #3393) set at 3000 lbs (1360.8 kg), at 190° C. for 5 minutes. The assembly of the mold and its contents were then cold-pressed in another Carver press that was set at 3000 lbs (1360.8 kg) with no heating for 30 minutes. The resulting laser-engraveable flexographic printing precursor (or laser-engraveable patternable element) was 75×75 mm in size and approximately 0.8 mm thick. This precursor was laser engraved using LES1 and the relief image depth when the laser fluence was 102 J/cm² was 301 μm. This precursor was further laser engraved using LES2 and the relief image depth was determined to be 45 μm. The edges of the laser engraved features were sharp, showing no melt edges. Minor amounts of debris were re-deposited onto the relief image and element.

Invention Example IE3

Thermoplastic elastomeric interpolymer alloy pellets (36 g, Alcryn® 4670BK containing 0.5 weight % of carbon black and 35 weight % of chlorine from Advanced Polymer Alloys) were combined with carbon black powder (2 g, Mogul® L from Cabot Corporation, Boston, Mass.) and melt mixed in a Brabender mixer (ATR-2120 equipped with 3 heat zones and high shear roller type blades) at 185° C. for 6 minutes, removed from the mixer, and allowed to cool. This resulted in a 94.8 weight % of Alcryn® and 5.2 weight % of carbon black. A sample (3.5 g) of this mixture was introduced into an aluminum mold with a sheet of 300FN Kapton™ on one side for ease of release, and was pressed into the shape of a flat plate using a Carver press (model #3393) set at 3000 lbs (1360.8 kg), at 190° C. for 5 minutes. The assembly of the mold and its contents were then cold-pressed in another Carver press that was set at 3000 lbs (1360.8 kg) with no heating for 30 minutes. The resulting laser-engraveable flexographic printing precursor (laser-engraveable patternable element) was 75×75 mm in size and approximately 0.8 mm thick.

Invention Example IE4

Thermoplastic elastomeric interpolymer alloy pellets (40 g, Alcryn® 2080BK containing 8 weight % of carbon black and 36 weight % of chlorine from Advanced Polymer Alloys) were combined with carbon black powder (2 g, Mogul® L from Cabot Corp Boston, Mass.) and 2 g of M5 Silica and melt mixed in a Brabender mixer (ATR-2120 equipped with 3 heat zones and high shear roller type blades) at 185° C. for 6 minutes, removed from the mixer, and allowed to cool. This resulted in a composition that contained a total of 11.8 weight % of carbon black and 4.6 weight % of silica. A sample (3.5 g) of this mixture was introduced into an aluminum mold with a sheet of 300FN Kapton™ on one side for ease of release, and was pressed into the shape of a flat plate using a Carver press (model #3393) set at 3000 lbs (1360.8 kg), at 190° C. for 5 minutes. The assembly of the mold and its contents were then cold-pressed in another Carver press that was set at 3000 lbs (1360.8 kg) with no heating for 30 minutes. The resulting laser-engraveable flexographic printing precursor (laser-engraveable patternable element) was 75×75 mm in size and approximately 0.8 mm thick. A portion of this flexographic printing precursor was reground under cryo-temperature conditions using liquid nitrogen, and then extruded using a ThermoHaake twin screw extruder (Model MiniLab Rheomix CTW5) at 185° C. for 10 minutes at 60 rpm, flushed from the extruder, and allowed to cool. Thin slices were taken and examined by optical microscopy, showing a uniform mixing of components. This example illustrates that the laser-engraveable flexographic printing precursor was readily reprocessed and recycled into a new precursor.

Invention Example IE5

A sample (3.5 g) of the thermoplastic elastomeric interpolymer alloy pellets (Alcryn® 2080BK containing 8 weight % of carbon black and 36 weight % of chlorine from Advanced Polymer Alloys) was introduced into an aluminum mold with a sheet of 300FN Kapton™ on one side for ease of release, and was pressed into the shape of a flat plate using a Carver press (model #3393) set at 3000 lbs (1360.8 kg), at 190° C. for 5 minutes. The assembly of the mold and its contents were removed and then cold-pressed in another Carver press that was set at 3000 lbs (1360.8 kg) with no heating for 30 minutes. The resulting laser-engraveable flexographic printing precursor (laser-engraveable patternable element) was 75×75 mm in size and approximately 0.8 mm thick. This precursor was laser engraved using LES1 and the relief image depth engraved when the laser fluence was 102 J/cm² was 164 μm. This precursor was further laser-engraved using LES2 and the relief image depth was determined to be 46 μm. The edges of the engraved precursor features were sharp, showing no melt edges, and the laser-engraved relief image and element were very clean, showing no re-deposition of debris sticking to them.

Invention Example IE6

A continuous roll of flexographic printing plate precursor was prepared by melt extruding, using a multi-purpose extruder (MPX), the thermoplastic elastomeric interpolymer alloy (TEIA) pellets (Alcryn® 2080BK containing 8 weight % of carbon black and 36 weight % of chlorine from Advanced Polymer Alloys). Twin screw extruders were used to feed the TEIA into a multiport temperature controlled 3 layer 7 inch (17.8 cm) EDI die with a 0.050 inch (0.13 cm) lip gap and the material was extruded onto a moving web of 125 μm thick polyethylene terephthalate (PET) substrate that had been coated with a primer layer that comprised a vinylidene chloride/acrylonitrile/acrylic acid terpolymer, as referred to in U.S. Pat. No. 5,695,920 (Anderson et al.). The TEIA/PET package was continuously taken up on a roller. The barrel zone 1 temp was 340° F. (188° C.), barrel zone 2&3 was 360° F. (182° C.) barrel zone 4, gate, adapter, polyline and die were at 370° F. (188° C.) on the MPX, and the thickness of the TEIA/PET package was varied between 425 and 1040 μm. The resulting laser-engraveable flexographic printing precursor (laser-engraveable patternable element) was laser engraved using LES2 and the relief image depth was determined to be 42 μm. The edges of the laser engraved features were sharp, showing no melt edges and the laser-engraved relief image and element were very clean, showing no redeposition of debris.

Invention Example IE7

A laser-engraveable element like Invention Example IE5 was prepared as noted above, except that the resulting size was 12 cm×20 cm by 0.8 mm thick. This precursor was laminated to a 0.265 mm thick PET [poly(ethylene terephthalate)] support with an adhesive layer on one side. The resulting assembly was mounted onto a rotating drum and was laser-engraved using LES3. The resulting imaged flexographic printing plate (flexographic printing member) was used for printing to a polyethylene film using a flexographic printing press (Comco Cadet 700) and a solvent-based cyan ink from Sun Chemical Corporation. The laser engraved flexographic printing plate showed excellent feature quality with no debris sticking to the relief image. After 5000 km of printing, both positive and negative images remained sharp. Vertical and horizontal 50 μm wide lines remained continuous and straight.

Invention Example IE8

A laser-engraveable element was prepared like Invention Example IE5 as above and was laser engraved using the LES2, except that the precursor was imaged using 15 sequential laser engraving passes at a speed of 0.2 msec. The resulting flexographic printing plate showed no image degradation or distortion, the relief image had sharp edges, showing no melt edges, and no debris sticking to it, even after undergoing a very high number of sequential engraving passes, having an overall relief image depth of 227 μm.

Comparative Example CE1

Polypropylene (Isotactic, M_(n)=250,000, Product #182389 from Sigma-Aldrich St. Louis, Mo.) was combined with carbon black powder (Mogul® L from Cabot Corporation, Boston, Mass.) in a weight ratio of 93:7 and melt mixed in a Brabender mixer (ATR-2120 equipped with 3 heat zones and high shear roller type blades) at 185° C. for 6 minutes, removed from the mixer, and allowed to cool. A sample (3.5 g) of this mixture was introduced into an aluminum mold and pressed as described for Invention Example IE1 at a temperature of 200° C. and 5000 lbs (2268.0 kg), and then cold pressed. The resulting laser-engraveable flexographic printing precursor was 75×75 mm in size and approximately 0.8 mm thick. This precursor was laser engraved using LES1 and the relief image depth that was laser engraved at a fluence of 102 J/cm², was 207 μm. The resulting flexographic printing member was very hard and did not show elastomeric properties. In addition, severe melt edges were observed at the edges of features in the relief image.

Comparative Example CE2

A styrene-butadiene triblock copolymer TPE (4.7 g, Kraton™ D1102K with 28% polystyrene content from Kraton Polymers LLC, Houston, Tex.) was combined with carbon black powder (0.3 g, Mogul® L from Cabot Corp Boston, Mass.) and melt mixed in a ThermoHaake twin screw extruder (Model MiniLab Rheomix CTW5) at 190° C. for 5 minutes at 60 rpm, flushed from the extruder, and allowed to cool. This resulted in 94 weight % of Kraton and 6 weight % of carbon black. A sample (3.5 g) of this mixture was melt molded as described for Invention Example IE1 and laser engraved using LES1, and the relief image depth when laser-engraved at a fluence of 102 J/cm² was 227 μm. However, the relief image showed melt edges. This precursor was further laser-engraved using LES2 and the relief image depth was determined to be 58 μm. However, the relief image showed melt edges.

Comparative Example CE3

Santoprene™ 111-73 (a thermoplastic vulcanizate consisting of vulcanized EPDM rubber micro-dispersed in a polyolefin, from ExxonMobil Chemical Company, TX) was melt-compounded with a carbon black concentrate (PolyOne® 1120 Black PEC Black, a 50% carbon loading in LDPE, from PolyOne, OH) to provide a final composition of 5 weight % of carbon in the thermoplastic vulcanizate, and injection molded at temperatures of 400-420° F. (204-232° C.) to provide square-shaped precursor samples that were 5 inch (12.7 cm) long×5 inch (12.7 cm) wide and 1.02-1.05 mm thick. The flexographic printing precursor was laser engraved using LES1 and further laser engraved using LES2. It was not possible to determine accurate depth values for the relief image due to the poor quality of the laser-engraving and resulting relief image features. The small 2% dots were not formed, and the relief image features were not well defined and did not have sharp edges. Melt edges and laser plowing were visible and sticky debris was re-deposited onto the relief image.

Comparative Example CE4

Sarlink® 3140 polypropylene elastomer blend thermoplastic vulcanizate (obtained from DSM Thermoplastic Elastomers, Inc., MA) was melt-compounded with carbon concentrate PolyOne® 1120 Black PEC Black as described above for Comparative Example CE3 to provide a final composition of 5 weight % of carbon in the thermoplastic vulcanizate, and injection molded at temperatures near 420° F. (216° C.) to provide square-shaped precursor samples that were 5 inch (12.7 cm) long, 5 inch (12.7 cm) wide, and 1.02-1.05 mm thick. The laser-engraveable patternable element was laser engraved using LES1 and further laser engraved using LES2. It was not possible to determine accurate relief image depths due to the poor quality of the laser engraving and the relief image features. The small 2% dots were not formed, and the relief image features were not well defined and did not have sharp edges. Melt edges and laser plowing were visible and sticky debris was re-deposited onto the relief image.

Comparative Example CE5

DuPont™ ETPV 60A01L (an engineering thermoplastic vulcanizate consisting of highly crosslinked vulcanized modified ethylene-acrylic rubber microdispersed in a copolyester matrix, from DuPont, DE) was melt-compounded with carbon concentrate Hytrel® Carbon Concentrate (from Clariant, N.C.) as described for Comparative Example CE3 to provide a final composition of 5 weight % carbon in the thermoplastic vulcanizate, and injection molded at temperatures of 245-255° C. to provide square-shaped laser-engraveable patternable element samples that were 5 inch (12.7 cm) long, 5 inch (12.7 cm) wide, and 1.02-1.05 mm thick. The patternable element was laser engraved using LES1 and further laser engraved using LES2. It was not possible to determine accurate relief image depths due to the poor quality of the laser-engraving and the relief image features. Most small and medium size dots and relief image features were very poorly defined. Extreme melt edges were observed.

Invention Example IE9 Gravure Element

Laser-engraveable patternable element IE5 was laser engraved using a LES2. The patterns used were either 10 μm wide lines that were 44 μm deep or 43 μm wide lines that were 44 μm deep arranged to cross in a diamond shaped pattern, to form a grid pattern in a gravure patternable element. The resulting patterned element was flooded with cyan solvent based ink (Flint Thermogloss Cyan) and the excess ink was skived off using a metal doctor blade, leaving the laser-engraved troughs filled with ink. The patterned element was then pressed onto paper receivers with various pressures to form printed images. The printed image line widths were of the same width as the laser-engraved troughs in the plate, and exhibited sharp and well defined edges.

Invention Example IE10 Recycling Method

To demonstrate how this patterned elements of this invention can be recycled, a flexographic printing member obtained from Invention Example IE5 (laser engraved using LES2) was cut into 5-10 mm size pieces using scissors. These pieces were then melt-molded in the press as described in Invention Example IE1. The resulting laser-engraveable printing precursors were 75×75 mm in size and approximately 0.8 mm thick. The laser-engraveable flexographic printing precursor (laser-engraveable patternable element) formed from this recycled material was laser-engraved using LES2, as described above. The relief image depth formed under the noted conditions was 44 μm, a similar relief depth as obtained for the non-recycled precursor of Example IE5. The edges of the laser engraved relief image features were sharp, showing no melt edges, and the relief image was very clean, showing no re-deposition of debris onto the relief image and element.

Invention Example IE11 Surface Patterning Prior to Laser-Engraving

Laser-engraveable Invention Example IE6, having a laser-engraveable layer on poly(ethylene terephthalate) with a total (TEIA/PET) thickness of 425 μM, was embossed by heat and pressure [using a Carver press (model #3393) set at 2000 lbs (907.2 kg) at 160° C. for 45 seconds] against a commercially available Flexcel™ NX (Kodak) flexographic printing plate having a surface relief pattern consisting of hemisphere-shaped depressions of 4 diameter and 2.6 μm deep, spaced 10 μm apart (center-to-center) as determined by a Veeco NT8000 system. This resulted in Invention Example IE5 laser-engraveable patternable element having a surface pattern having raised hemispheres (the mirror or inverse image) of the same size and spacing as above. A full relief image at a lower repeat frequency was then laser-engraved into this surface-patterned laser-engraveable precursor using LES2. This fully laser engraved patterned element was then used to print impressions on paper receivers (KPP-Proofing paper) using a benchtop K Printing Proofer (Testing Machines Inc. DE) and an aqueous cyan ink (HMR50080-473 process cyan from Flint, Minn.) using a 150 lpi Anilox plate.

Invention Example IE12 Surface Patterning Prior to Laser-Engraving

Another surface pattern was obtained by laser engraving another portion of Invention Example IE5 using LES2. The micro-surface pattern used was a checkerboard pattern of 30 μm wide×30 μm long spots, each engraved to a depth of 13 μm. The surface patterned laser-engraved patternable element was then laser engraved to form a relief image using LES2 at a lower frequency of repetition.

The examples described above demonstrate that the thermoplastic elastomeric interpolymer alloy described for use in the present invention provides a unique required combination of properties for high precision laser-engraveable patternable elements, providing excellent engraved image quality, absence of melt edges, laser-engraveable cleanliness, and no re-deposition of debris onto the relief images, compared to the comparative laser-engraveable patternable elements.

The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. 

The invention claimed is:
 1. A method for providing a pattern of a functional material, the method comprising: imagewise exposing a laser-engraveable patternable element that comprises at least one laser-engravable layer comprising a thermoplastic elastomeric interpolymer alloy that comprises: a non-crosslinked halogenated polymer, a partially crosslinked polyolefin, and a polyester, to laser-engraving radiation to provide a directly laser-engraved patterned element having a relief image in the laser-engraveable layer, and using the directly laser-engraved patterned element to print a pattern of a functional material.
 2. The method of claim 1, wherein the laser-engraveable patternable element is a flexographic printing precursor and the relief image in the laser-engraveable layer has a minimum relief image depth of at least 30 μm.
 3. The method of claim 1, wherein the laser-engraveable patternable element is a gravure or intaglio printing precursor and the relief image is the laser-engraveable layer has a minimum relief image depth of at least 10 μm.
 4. The method of claim 1, comprising imagewise exposing using one or more near-infrared radiation emitting lasers and the laser-engraveable layer further comprises a near-infrared radiation absorber in an amount of at least 0.5 weight %.
 5. The method of claim 1, comprising: applying a functional material to a raised surface of the directly laser-engraved patterned element having a relief image that has a minimum relief image depth of at least 10 μm, to form a film of the functional material on the raised surface of the relief image, and contacting the film of the functional material with a receiver element to form a pattern of the functional material on the receiver element that corresponds to the relief image.
 6. The method of claim 1, comprising: using the laser-engraved patterned element to print a pattern with a functional material comprising nanoparticles of an electrically conductive material selected from the group consisting of silver, gold, copper, palladium, indium-tin oxide, and combinations thereof.
 7. The method of claim 1, wherein the functional material is selected from the group consisting of electrically conductive materials, semi-conductive materials, dielectric materials, small molecule materials, polymeric materials, bio-based materials, and combinations thereof.
 8. The method of claim 1, wherein the non-crosslinked halogenated polymer is present in the laser-engraveable layer in an amount of at least 5 weight % and up to and including 75 weight %, based on the total dry weight of the laser-engraveable layer.
 9. The method of claim 1, wherein the partially crosslinked polyolefin is present in the laser-engraveable layer in an amount of at least 5 weight % and up to and including 90 weight %, based on the total dry weight of the laser-engraveable layer.
 10. The method of claim 1, wherein the polyester is present in the laser-engraveable layer in an amount of at least 5 weight % and up to and including 90 weight %, based on the total dry weight of the laser-engraveable layer.
 11. The method of claim 1, wherein the thermoplastic elastomeric interpolymer alloy has a softening temperature of less than or equal to 10° C.
 12. The method of claim 1, wherein the laser-engraveable layer further comprises a near-infrared radiation absorber in an amount of at least 0.5 weight %, which near-infrared radiation absorber is a carbon black, carbon nanotubes, an inorganic or organic pigment, an organic dye having at least one absorption peak wavelength of at least 700 nm to and including 1400 nm, or a combination of any of these materials.
 13. The method of claim 1, wherein the laser-engraveable patternable element comprises multiple layers including at least one laser-engraveable layer.
 14. The method of claim 1, wherein the laser-engraveable patternable element further comprises a substrate over which the laser-engraveable layer is disposed.
 15. The method of claim 1 for providing a pattern comprising lines having an average line width of less than 20 μm.
 16. The method of claim 1 for providing a pattern of functional material that comprises a seed material for a subsequent plating process.
 17. The method of claim 1 for providing a pattern of functional material that is formulated to protect an underlying uniform metal film during a subsequent etching process.
 18. The method of claim 1, comprising using the directly laser-engraved patterned element to print a pattern of a functional material onto a substrate or a layer on a substrate.
 19. The method of claim 18, wherein the pattern of a functional material is printed onto a primer layer, adhesive layer, charge injection layer, charge transporting layer, or semiconducting layer on a substrate. 